Addition Of Fugitive Material Patents (Class 419/36)
  • Patent number: 11577315
    Abstract: The present application provides a 3D printing method. The present application can provide as a method for efficiently performing 3D printing, for example, a 3D printing method capable of more rapidly and efficiently producing a three-dimensional shape precisely realized up to a fine portion.
    Type: Grant
    Filed: April 3, 2017
    Date of Patent: February 14, 2023
    Inventors: Dong Woo Yoo, Jin Kyu Lee
  • Patent number: 11582884
    Abstract: Methods and system are provided for a heat exchanger. In one example, a system, comprises a mobile electronic device comprising a front cover and a rear cover, a heat exchanger arranged between the front cover and the rear cover, the heat exchanger comprising a fluid chamber arranged between an inner surface of a first plate and an inner surface of a second plate, and a wick material arranged within the fluid chamber, the wick material comprising a sintered material configured to allow a plurality of fluid passages to extend therethrough.
    Type: Grant
    Filed: January 2, 2020
    Date of Patent: February 14, 2023
    Assignee: Dana Canada Corporation
    Inventor: Doug Vanderwees
  • Patent number: 11554536
    Abstract: A method may include fused filament fabricating a fused filament fabricated component by delivering a softened filament to selected locations at or adjacent to a build surface. The softened filament may include a sacrificial binder and a powder including a shape memory alloy (SMA). The method also may include removing substantially all the sacrificial binder from the fused filament fabricated component to leave an unsintered component; and sintering the unsintered component to join particles of the SMA and form an SMA component.
    Type: Grant
    Filed: November 13, 2020
    Date of Patent: January 17, 2023
    Assignees: Rolls-Royce Corporation, Rolls-Royce North American Technologies, Inc.
    Inventors: Quinlan Yee Shuck, Scott Nelson, Raymond Ruiwen Xu, Brandon David Ribic, Matthew R. Gold
  • Patent number: 11534964
    Abstract: Provided is a method which includes a first layer formation step of forming a first layer by using a first composition that contains a constituent material powder, a first powder, and a binder of a three-dimensional shaped article; a second layer formation step of forming a second layer by using a second composition that contains a second powder and a binder; a degreasing step of a stack containing the first layer and the second layer; and a sintering step of the stack, a decomposition point of the first powder is higher than decomposition points of the binder of the first layer and the binder of the second layer, a decomposition point of the second powder is higher than the decomposition point of the first powder, and a sintering temperature of the constituent material powder is higher than the decomposition point of the second powder.
    Type: Grant
    Filed: November 29, 2018
    Date of Patent: December 27, 2022
    Inventors: Eiji Okamoto, Akihiko Tsunoya
  • Patent number: 11524457
    Abstract: A fabrication device includes a build surface to receive layers of material for production of a 3-dimensional solid representation of a digital model and an imaging component to bind respective portions of the build material into cross sections representative of portions of data contained in the digital model. The imaging component may be a programmable planar light source utilizing a micropixelation system and refractive pixel shifting mechanism, or other imaging system. The device may include a system for controlling the density of the printed part. The object may be a powder composite component using any of a variety of powder materials or a plastic component. The object may be further post-processed to produce a high precision metal or ceramic component.
    Type: Grant
    Filed: November 12, 2021
    Date of Patent: December 13, 2022
    Assignee: TRIO LABS, INC.
    Inventor: Adam T. C. Steege
  • Patent number: 11527944
    Abstract: A method of making a component of an electrical machine is provided. An additive manufacturing process is used to manufacture a part, including applying beams of energy to a successive plurality of ferromagnetic material particles and fusing them together to form a ring or segment of a ring with an axis, a solid portion, and laminas that extend from the solid portion in a radial or axial direction.
    Type: Grant
    Filed: December 7, 2015
    Date of Patent: December 13, 2022
    Inventors: Anoop Jassal, Jan Erich Hemmelmann, Mohamed Osama
  • Patent number: 11524337
    Abstract: A powder for additive manufacturing, which is a powder to be used in a three-dimensional additive manufacturing method, including a plurality of coated particles containing metal particles, and resin coating films that cover the metal particles and contain a caking additive, wherein 0.0001?t/D50?0.0010 in which t is an average thickness of the resin coating films and D50 is an average particle diameter of the metal particles.
    Type: Grant
    Filed: September 10, 2020
    Date of Patent: December 13, 2022
    Inventors: Hidefumi Nakamura, Atsushi Nakamura, Toshiki Sano, Naoko Shima
  • Patent number: 11491542
    Abstract: A system for fabricating an infiltrated downhole tool for introduction into a wellbore includes a mold assembly including a binder bowl, a mold, a preformed blank, and a funnel. The binder bowl has a lower portion and a plurality of apertures extending through the lower portion. The preformed blank is disposed within the infiltration chamber to provide an attachment area for a body of the infiltrated downhole tool, and the funnel is disposed intermediate the binder bowl and the mold. The system further includes a binder flow channel which extends through at least one of the preformed blank, the funnel, or a displacement core disposed within the mold assembly, the blank being concentrically arranged around the displacement core.
    Type: Grant
    Filed: August 16, 2017
    Date of Patent: November 8, 2022
    Assignee: Halliburton Energy Services, Inc.
    Inventors: Yi Pan, Daniel Brendan Voglewede, Grant O. Cook, III, Jeffrey G. Thomas
  • Patent number: 11466169
    Abstract: There is provided a piezoelectric composite comprising a piezoelectric polymer and particles of a filler dispersed in the polymer, wherein the filler is in micro or nanoparticle form and is present in a filler:polymer weight ratio between about 1:99 and about 95:5. There is also provided an ink and ink cartridge for 3D printing of the piezoelectric composite. There is also provided a piezoelectric 3D printed material comprising the piezoelectric composite and a bifunctional material comprising the piezoelectric composite with one or more conductive electrodes adjacent to the piezoelectric composite. Methods of manufacture and uses thereof are also provided, including methods for 3D printing of a piezoelectric 3D printed material via solvent-cast or FDM 3D printing starting from the piezoelectric composite and/or the ink.
    Type: Grant
    Filed: November 10, 2017
    Date of Patent: October 11, 2022
    Inventors: Sampada Bodkhe, Daniel Therriault, Frédérick Gosselin, Tao Rui
  • Patent number: 11447423
    Abstract: The present invention is a method for obtaining a ceramic slurry for the production of filaments for 3D FDM printing, comprising adding a polysaccharide, a glycol or an ethanolamine as a gelling agent to a suspension of ceramic material in order to produce said ceramic slurry. The invention also comprises the green body obtained from said slurry and the ceramic filament extruded from the green body.
    Type: Grant
    Filed: April 4, 2017
    Date of Patent: September 20, 2022
    Inventors: Jesús Canales Vázquez, Gloria Begoña Sánchez Bravo, Juan Ramón Marín Rueda, Vicente Yagüe Alcaraz, Juan José López López
  • Patent number: 11426798
    Abstract: An additive manufacturing technique may include forming, on a surface of a substrate, a layer of material using an additive manufacturing technique. The material may include a sacrificial binder and a powder comprising an oxide-dispersion strengthened alloy dispersed in the binder. The technique may include forming, on the layer of material, at least one additional layer of material to form an additively manufactured component. The binder may be selectively sacrificed to leave the powder, for example, to form a component including an alloy.
    Type: Grant
    Filed: April 25, 2019
    Date of Patent: August 30, 2022
    Assignee: Rolls-Royce Corporation
    Inventor: Quinlan Yee Shuck
  • Patent number: 11426929
    Abstract: Provided is a powder material for producing a three-dimensional object including: a base material; a resin; and resin particles, wherein an amount W (mass %) of carbon remaining in the powder material after heating in a vacuum of 10?2 Pa or lower at 450 degrees C. for 2 hours satisfies the following formula: W (mass %)<0.9/M, where M represents the specific gravity of the base material.
    Type: Grant
    Filed: July 1, 2020
    Date of Patent: August 30, 2022
    Assignee: RICOH COMPANY, LTD.
    Inventors: Junjiroh Sogame, Kohsuke Miyazaki, Takumi Yokoyama, Shinichiroh Satoh, Takafumi Sasaki, Osamu Mizuta, Hiroyuki Miyata, Naoki Oya
  • Patent number: 11111563
    Abstract: Composites comprising various fractions of ultra coarse (UC) tungsten carbide (WC) and cast carbide (CC), along with composites comprising fractions of UC-WC and CC having various particle size and showing an improved strength and erosion resistance, and methods for making the inventive composites.
    Type: Grant
    Filed: September 10, 2018
    Date of Patent: September 7, 2021
    Inventors: Ravi K. Enneti, Kevin Prough, Keith Newman
  • Patent number: 10898951
    Abstract: Powder particles for forming a homogeneous green body having a sufficient strength and a process for producing a green body by using the powder particles. A green body is shaped by using powder particles of composite particles in which thermoplastic resin particles are scattered on surfaces of large particles in an amount within a predetermined volume ratio range with respect to the large particles, and loaded to form resin pools in contact point peripheral areas of adjoining ones of the large particles and form voids in areas other than the contact point peripheral areas when the thermoplastic resin particles are melted. A green body packed with the powder particles each having a small amount of the thermoplastic resin particles attached thereon is placed under a melting condition of the thermoplastic resin particles, the thermoplastic resin is melted and gathers around contact points (or proximal points) of the adjoining powder particles.
    Type: Grant
    Filed: December 11, 2016
    Date of Patent: January 26, 2021
    Assignee: National University Corporation TOYOHASHI UNIVERSITY OF TECHNOLOGY
    Inventors: Hiroyuki Muto, Atsunori Matsuda, Go Kawamura, Tatsuya Matsusaki
  • Patent number: 10675682
    Abstract: A compound for metal powder injection molding includes secondary particles in which first metal particles are bound to one another, and a matrix region including a binder and second metal particles composed of the same constituent material as the first metal particles and having a smaller average particle diameter than the first metal particles. The constituent material of the first metal particles is any of an Fe-based alloy, an Ni-based alloy, and a Co-based alloy.
    Type: Grant
    Filed: February 22, 2018
    Date of Patent: June 9, 2020
    Assignee: Seiko Epson Corporation
    Inventors: Hidefumi Nakamura, Yasutoshi Hideshima
  • Patent number: 10608417
    Abstract: A spark plug having a center conductor, an insulator surrounding the center conductor, at least two electrodes forming a spark gap, and a spark plug body surrounding the insulator and having an external thread arranged at the front end of the spark plug for screwing in to an internal combustion engine. A component that is attached to the front end of the spark plug and comes into contact with fuel during operation is formed as a sintered powder injection molded part, referred to as a metal injection molded (MIM) component.
    Type: Grant
    Filed: June 7, 2018
    Date of Patent: March 31, 2020
    Inventors: Werner Niessner, Alexander Schenk
  • Patent number: 10583487
    Abstract: A method of producing a finished essentially 100% dense homogenous alloyed metallic product. First, a metal powder is provided comprised of particles with each particle having a predetermined alloy content. Next, the metal powder is blended with a mixture of a lubricant and a binder to form a composite powder. That composite powder is then compacted in a compacting die at room temperature to form a green part. The lubricant and binder are then removed by heating the green part to at least a first temperature profile in a confined atmosphere with a predetermined dew point profile. Next, the remaining green part is heated to a second temperature higher than the first temperature and with predetermined dew point and H2/H2O ratio in a furnace atmosphere to remove surface oxides from the part. Finally, the part is densified into a finished or near net shape homogenous alloyed product.
    Type: Grant
    Filed: December 3, 2015
    Date of Patent: March 10, 2020
    Assignee: TAT Technologies LLC
    Inventor: Harbhajan S. Nayar
  • Patent number: 10569332
    Abstract: A moulding tool for powder injection moulding a cemented carbide or cermet component includes a through hole. The moulding tool further includes at least a first and a second tool part arranged to define at least one mould cavity for forming a component. At least one inlet channel introduces moulding material into the mould cavity. The inlet channel extends through the first tool part to the mould cavity, and has an outlet end having an outlet opening for discharging moulding material from the inlet channel into the mould cavity. At least one core forms a through hole in the component, the core having an end and being arranged to extend into the mould cavity along a longitudinal axis (X) in a direction towards the outlet opening of the inlet channel. The end of the core is arranged to close the outlet opening of the inlet channel and the core is arranged movably along the longitudinal axis (X) such that the end of the core may engage with the outlet opening of the inlet channel.
    Type: Grant
    Filed: September 28, 2016
    Date of Patent: February 25, 2020
    Inventor: Carl-Åke Gunnar Jansson
  • Patent number: 10434571
    Abstract: A method for manufacturing a powder injection molding feedstock includes providing a plurality of powder particles and a secondary binder and applying primary kneading in an internal mixer. The primary mixture is cooled and crushed. A main binder is provided and put into the internal mixer to mix with the mixture that being crushed for secondary kneading to obtain the powder injection molding feedstock. Glass-transition temperature of the secondary binder is greater than glass-transition temperature of the main binder. The secondary binder coats the powder particles. The main binder coats the secondary binder and the powder particles.
    Type: Grant
    Filed: October 26, 2017
    Date of Patent: October 8, 2019
    Inventors: Dung-Chang Yeh, Lei Yan, Ru-Jie Huang
  • Patent number: 10213834
    Abstract: A method of fabricating an article for magnetic heat exchange, is provided which comprises plastically deforming a composite body comprising a binder having a glass transition temperature TG and a powder comprising a magnetocalorically active phase or elements in amounts suitable to produce a magnetocalorically active phase such that at least one dimension of the composite body' changes in length by at least 10%.
    Type: Grant
    Filed: June 2, 2016
    Date of Patent: February 26, 2019
    Assignee: Vacuumschmelze GmbH & Co. KG
    Inventors: Hugo Abdiel Vieyra Villegas, Matthias Katter, Barcza Alexander
  • Patent number: 10072563
    Abstract: An exhaust-gas turbocharger (1) having a turbine (2) which is provided with an adjustable turbine geometry and/or with a wastegate; and having an actuator (11) which is connected by means of a coupling rod (14; 14?; 14?) to the adjustable turbine geometry and/or to the wastegate. The coupling rod (14; 14?; 14?) is connected at its end regions at one side to the actuator (11) and at the other side to an adjusting shaft arrangement of the variable turbine geometry and/or of the wastegate. The coupling rod (14; 14?; 14?) is formed as an MIM component.
    Type: Grant
    Filed: June 10, 2013
    Date of Patent: September 11, 2018
    Assignee: BorgWarner Inc.
    Inventors: Volker Paul, Nico Kanoffsky
  • Patent number: 9844811
    Abstract: Provided is a raw material powder for powder metallurgy, capable of preventing stains, surface defects and decarburization of a sintered body, improving strength and density thereof. The raw material powder for powder metallurgy is for use in the production of a sintered body that is sintered at a temperature of not lower than 500° C., composed of a mixture of a metal powder and a lubricant, in which the lubricant is melamine cyanurate or terephthalic acid. Alternatively, the raw material powder for powder metallurgy is for use in the production of a sintered body that is sintered at a temperature of not lower than 500° C, composed of a mixture of a metal powder, a first lubricant and a second lubricant, in which the first lubricant is melamine cyanurate or terephthalic acid, while the second lubricant is preferably erucic acid amide or stearic acid amide.
    Type: Grant
    Filed: December 2, 2013
    Date of Patent: December 19, 2017
    Inventors: Takashi Nakai, Kinya Kawase
  • Patent number: 9713586
    Abstract: An oral care composition comprising a diluted sodium calcium alginate gel, wherein the oral care composition is a toothpaste, a gel, a mouthwash or a mouthrinse.
    Type: Grant
    Filed: September 17, 2013
    Date of Patent: July 25, 2017
    Assignee: Colgate-Palmolive Company
    Inventors: Manying Shi, Xiaojing Lv, Rolando Plata, Zhuoxing Zhang
  • Patent number: 9617394
    Abstract: Particles for forming interconnected or continuous layers of material are, in some embodiments, composed of a Material A, a first central material comprising at least one meltable, softenable, or sinterable substance, and Material B, a second substantially thin material applied to the outer surface of said first material which is thermally or mechanically breachable.
    Type: Grant
    Filed: April 15, 2016
    Date of Patent: April 11, 2017
    Assignee: AeonClad Coatings, LLC
    Inventors: Robert Scott Evans, Daniel John Verdell Pulsipher, John Stockton
  • Patent number: 9475945
    Abstract: An aqueous slurry that is useful upon being spray dried for the formation of a powder of hard material. The aqueous slurry includes starting powder components of the hard material. The slurry further includes an oxidation inhibitor, a surfactant in an amount between about 0.05 weight percent and about 0.30 weight percent of the weight of the starting powder components of the hard material, a binder, a defoamer and water in an between about 15 weight percent and about 30 weight percent of the weight of the weight of the starting powder components of the hard material. The aqueous slurry has a percent solids value that is between about 70 percent and about 85 percent.
    Type: Grant
    Filed: October 3, 2013
    Date of Patent: October 25, 2016
    Assignee: KENNAMETAL INC.
    Inventors: Pankaj B. Trivedi, Pankaj K. Mehrotra, Neal S. Myers
  • Patent number: 9469543
    Abstract: Refractory metal and refractory metal carbide nanoparticle mixtures and methods for making the same are provided. The nanoparticle mixtures can be painted onto a surface to be coated and heated at low temperatures to form a gas-tight coating. The low temperature formation of refractory metal and refractory metal carbide coatings allows these coatings to be provided on surfaces that would otherwise be uncoatable or very difficult to coat, whether because they are carbon-based materials (e.g., graphite, carbon/carbon composites) or temperature sensitive materials (e.g., materials that would melt, oxidize, or otherwise not withstand temperatures above 800° C.), or because the high aspect ratio of the surface would prevent other coating methods from being effective (e.g., the inner surfaces of tubes and nozzles). The nanoparticle mixtures can also be disposed in a mold and sintered to form fully dense components.
    Type: Grant
    Filed: May 2, 2014
    Date of Patent: October 18, 2016
    Assignee: Lockheed Martin Corporation
    Inventor: Alfred A. Zinn
  • Patent number: 9336922
    Abstract: A fabrication method of thermoelectric materials using core-shell structured nano-particles and thermoelectric materials fabricated by the same are provided. The method includes preparing core-shell structured nano-particles having thermoelectric elements coated on the surface thereof (step 1); adding and mixing the prepared core-shell structured nano-particles of step 1, bismuth (Bi) salts, tellurium (Te) salts and a surfactant in a solvent (step 2); adding and dispersing a reducing agent in the mixture of step (step 3); and heating the mixture of step 3 in which reducing agent is added and dispersed (step 4). According to the present invention, thermoelectric materials, nano-phase is homogeneously dispersed inside of thermoelectric grain boundary, can be fabricated and if the fabricated materials are used after sintering and bulking, the thermoelectric materials are maintained in a state that the nano-particles remain in dispersed phase even after sintering.
    Type: Grant
    Filed: July 18, 2012
    Date of Patent: May 10, 2016
    Assignee: Korea Institute of Machinery and Materials
    Inventors: Kyung Tae Kim, Gook Hyun Ha
  • Patent number: 9308584
    Abstract: Sintered fiber filters are provided that can afford high particle capture efficiency and/or low pressure drop during operation, and are useful in applications such as semiconductor processing. The shape of at least a portion of the individual fibers (e.g., metal fibers) used to make the filter have a three-dimensional aspect, which allows for a low packing density and high porosity filtration media. Certain filters have a cylindrical or tube-like shape with tapered ends of higher density. Methods of making such filters, for example, using axial pressing, are also described.
    Type: Grant
    Filed: January 22, 2014
    Date of Patent: April 12, 2016
    Inventors: Derek Burgess, Wayne F. White, Alfred M. Romano, Todd W. Pflugbeil, Richard D. Balazy, Kenneth L. Rubow, John E. Rosenberger
  • Patent number: 9289946
    Abstract: Three-dimensional printing system with automated part removal. In one embodiment, the system includes a printing surface on which a part is made and a printing device supported for controlled movement with respect to the printing surface to print the part on the printing surface. A blade is supported for motion across the printing surface to release the part from the printing surface. The present printing system according to the invention requires fewer user steps than known in the prior art.
    Type: Grant
    Filed: January 16, 2014
    Date of Patent: March 22, 2016
    Assignee: Massachusetts Institute of Technology
    Inventors: Alfonso Alexander Perez, Christopher Michael Haid, Forrest W. Pieper, Mateo Pena Doll
  • Patent number: 9054477
    Abstract: Frames for plug connectors capable of being a reduced size may include features to support contacts, house circuitry for coupling with the contacts, facilitate the flow of molten material during the molding of the frame, and allow for ease of insertion and removal of the plug connector to and from a corresponding receptacle connector. For example, a frame may include ledges, interlocks and rounded and tapered openings. Methods for manufacturing the frame are also provided.
    Type: Grant
    Filed: September 11, 2012
    Date of Patent: June 9, 2015
    Assignee: Apple Inc.
    Inventors: Michael Brickner, Wayne Cowan, Brett A. Rosenthal, Richard Heley, Mathias W. Schmidt
  • Publication number: 20150125334
    Abstract: A process and materials are disclosed to enable the formation of metal powder-polymer/plastic preform articles by three dimensional printing a green state article, debinding the polymer/plastic from the metal powder, and sintering the article to a final shape.
    Type: Application
    Filed: November 1, 2013
    Publication date: May 7, 2015
    Applicant: American Hakko Products, Inc.
    Inventors: Takashi Uetani, Chris Stuber
  • Patent number: 8951465
    Abstract: A method for preparing an implant having a porous metal component. A loose powder mixture including a biocompatible metal powder and a spacing agent is prepared and compressed onto a metal base. After being compressed, the spacing agent is removed, thereby forming a compact including a porous metal structure pressed on the metal base. The compact is sintered, forming a subassembly, which is aligned with a metal substrate portion of an implant. A metallurgical bonding process, such as diffusion bonding, is performed at the interface of the subassembly and the metal substrate to form an implant having a porous metal component.
    Type: Grant
    Filed: February 25, 2013
    Date of Patent: February 10, 2015
    Assignee: Biomet Manufacturing, LLC
    Inventor: Gautam Gupta
  • Patent number: 8916090
    Abstract: The invention provides an endoscope having a lens holder, wherein the lens holder comprises a body containing a sintered feedstock and machined surfaces. The invention also provides a method of manufacturing the endoscope which comprises the steps of molding a metal blank by a MIM process, wherein the metal blank is “near net shape” and has a sprue, a post, and optionally an outer shell, machining the inner surfaces and then the outer surfaces of the metal blank to form a lens holder, installing a lens in the lens holder, and assembling the lens holder having the lens into the endoscope.
    Type: Grant
    Filed: July 7, 2011
    Date of Patent: December 23, 2014
    Assignee: Karl Storz Imaging, Inc.
    Inventor: Kin Ming Kwan
  • Patent number: 8911662
    Abstract: A powder for use in the powder metallurgical manufacture of components is provided. Particularly the subject matter concerns an iron or iron based powder intended for the powder metallurgical manufacturing of components. It is especially suitable for manufacturing of components wherein self-lubricating properties are desired. The subject matter further relates to a method of manufacturing a component from said powder and an accordingly produced component. A diffusion-bonded powder comprising iron or iron-based particles, and particles diffusion-bonded to the iron or iron-based particles is provided. The said particles diffusion-bonded to the iron or iron-based particles may comprise an alloy of Cu and 5% to 15% by weight of Sn. A component is provided which is at least partly formed from such a diffusion-bonded powder.
    Type: Grant
    Filed: December 28, 2007
    Date of Patent: December 16, 2014
    Assignee: Hoganas AB
    Inventor: Mats Larsson
  • Patent number: 8911663
    Abstract: The present invention relates to ferromagnetic powders with an electrically insulating layer on iron particles intended for the manufacture of components having improved soft magnetic properties at low and medium frequencies. The invention comprises an iron powder coated with a dielectric insulating layer comprising boron bearing compounds to form an insulated ferromagnetic powder. The present invention also relates to a method of making these insulated ferromagnetic powders. The present invention further relates to a method of synthesizing a product made from insulated ferromagnetic powders via a post-heat treatment at a moderate temperature (300° C. to 700° C.), to form a glass-like coating which acts as an electrical insulator. A preferred embodiment of the present invention is obtained when small amounts of alkali bearing compounds are added to the precursors to modify the coating chemistry and significantly increase the electrical resistivity after heat treatment.
    Type: Grant
    Filed: March 5, 2009
    Date of Patent: December 16, 2014
    Assignee: Quebec Metal Powders, Ltd.
    Inventors: Guillem Vachon, Claude Gelinas
  • Patent number: 8871142
    Abstract: Provided are methods for processing a green body that includes compacted metal powder, comprising impacting the green body with a particulate material for a time and under conditions effective to displace a portion of the metal powder from the green body. The present methods can be used to prepare green bodies that have “roughened” surfaces and that can be used to make orthopedic implants displaying low movement relative to bone when installed in situ, which corresponds to higher stability upon implantation and decreases the time required for biological fixation of the implant. Also provided are implants comprising a metallic matrix, and methods comprising surgically installing an implant prepared from a “surface roughened” green body in accordance with the present invention.
    Type: Grant
    Filed: May 21, 2009
    Date of Patent: October 28, 2014
    Assignee: DePuy Synthes Products, LLC
    Inventors: Bryan Smith, Jeffrey A. Rybolt, Derek Hengda Liu, Andrew James Martin
  • Patent number: 8858675
    Abstract: A powder metallurgical combination is provided comprising an iron-based powder A comprising core particles of iron to which core particles nickel is diffusion alloyed and wherein said nickel diffusion alloyed to said core particles comprises 4-7% (preferably 4.5-6%) by weight of said iron-based powder A, and a powder B substantially consisting of particles of pure iron. Further a method is provided for preparing a powder metallurgical combination.
    Type: Grant
    Filed: July 10, 2008
    Date of Patent: October 14, 2014
    Assignee: Hoganas AB (Publ)
    Inventor: Mats Larsson
  • Patent number: 8852498
    Abstract: A process for fabricating hollow metal shells such as Be or Al filled with a selected gas such as D or T. An organic preform is coated with a slurry of organic binder and metal powder of Be or Al. The coated preform is heated to remove the preform and any organics to form a hollow shell which is then fired at an elevated temperature in a gas so as to seal the shell and capture the gas inside the sealed shell.
    Type: Grant
    Filed: April 20, 2012
    Date of Patent: October 7, 2014
    Assignee: Imaging Systems Technology, Inc.
    Inventor: Carol Ann Wedding
  • Patent number: 8840832
    Abstract: Material processing systems are disclosed. Some systems include methods of eliminating or reducing defects in elongate workpieces that can undergo large deformations during processing. Some systems include apparatus configured to facilitate such large deformations while maintaining internal stresses (e.g., tensile stresses) below a threshold stress. Some disclosed systems pertain to powder extrusion techniques. Continuous and batch processing systems are disclosed.
    Type: Grant
    Filed: March 2, 2011
    Date of Patent: September 23, 2014
    Assignee: Accellent Inc.
    Inventors: Mark W. Broadley, James Alan Sago, John Eckert, Jeffrey M. Farina
  • Patent number: 8834785
    Abstract: A method for producing a metal article according to one embodiment may involve the steps of: Providing a composite metal powder including a substantially homogeneous dispersion of molybdenum and molybdenum disulfide sub-particles that are fused together to form individual particles of the composite metal powder; and compressing the molybdenum/molybdenum disulfide composite metal powder under sufficient pressure to cause the mixture to behave as a nearly solid mass.
    Type: Grant
    Filed: July 11, 2011
    Date of Patent: September 16, 2014
    Assignee: Climax Engineered Materials, LLC
    Inventors: Matthew C. Shaw, Carl V. Cox, Yakov Epshteyn
  • Patent number: 8828312
    Abstract: Forming a wear- and corrosion-resistant coating on an industrial component such as a chemical processing or nuclear power valve component by applying a cobalt-based dilution buffer layer to an iron-based substrate by slurry coating, and then applying by welding a cobalt-based build-up layer over the cobalt-based dilution buffer layer. An industrial component having a dilution buffer layer and a welding build-up layer thereover.
    Type: Grant
    Filed: December 8, 2011
    Date of Patent: September 9, 2014
    Assignee: Kennametal Inc.
    Inventors: Matthew Yao, Rachel Collier, Danie DeWet
  • Publication number: 20140227124
    Abstract: A ferrous alloy for powder injection molding is provided. The ferrous alloy for powder injection molding includes iron (Fe) at 52.59-78.15 wt %, chromium (Cr) at 16.45-37.34 wt %, boron (B) at 3.42-7.76 wt %, silicon (Si) at 1.64-1.92 wt %, sulfur (S) at 0-0.21 wt %, carbon (C) at 0.16-0.18 wt %, and other inevitable impurities.
    Type: Application
    Filed: April 20, 2012
    Publication date: August 14, 2014
    Inventors: Sung Hak Lee, Byeong-Joo Lee, Jeonghyeon Do, Yang Su Shin
  • Patent number: 8790571
    Abstract: A method for preparing an article is disclosed. The method comprises compacting a mixture of a first pre-alloyed powder and a lubricant to thereby form a green part having a green strength sufficient to permit mechanical handling; applying a slurry to a surface of the green part to thereby form a slurry coated green part, wherein the slurry comprises a second pre-alloyed powder, a binder, and a solvent; and heating the coated green part to a temperature below a solidus temperature of the first pre-alloyed powder and between a solidus temperature and a liquidus temperature of the second pre-alloyed powder to thereby solid state sinter the first pre-alloyed powder into a sintered core and to liquid state sinter the second pre-alloyed powder into a continuous alloy coating over the sintered core.
    Type: Grant
    Filed: May 28, 2009
    Date of Patent: July 29, 2014
    Assignee: Kennametal Inc.
    Inventors: Abdelhakim Belhadjhamida, Donald Williams, John Davies
  • Patent number: 8747516
    Abstract: Flowability-improving particles are adhered to surfaces of iron powder through a binder to provide an iron-based powder for powder metallurgy which has excellent flowability and which is capable of uniformly filling a thin-walled cavity and compaction with high performance of ejection force.
    Type: Grant
    Filed: December 13, 2007
    Date of Patent: June 10, 2014
    Assignee: JFE Steel Corporation
    Inventors: Tomoshige Ono, Shigeru Unami, Takashi Kawano, Yukiko Ozaki
  • Patent number: 8734561
    Abstract: A bonded metallurgical powder composition including: an iron-based powder having a weight average particle size in the range of 20-60 ?m, in an amount of at least 80 percent by weight of the composition, graphite powder in an amount between 0.15-1.0 percent by weight of the composition, a binding agent in an amount between 0.05-2.0 percent by weight of the composition, a flow agent in an amount between 0.001-0.2 percent by weight of the composition; wherein the graphite powder is bound to the iron-based powder particles by means of the binding agent, and wherein the powder composition has an apparent density of at least 3.10 g/cm3 and a hall flow rate of at most 30 s/50 g. Also, a method for producing a sintered component with improved strength from the inventive composition, as well as to a heat treated sintered component produced according to said method.
    Type: Grant
    Filed: October 26, 2010
    Date of Patent: May 27, 2014
    Assignee: Hoganas AB (Pub)
    Inventor: Mats Larsson
  • Patent number: 8734715
    Abstract: A method for preparing a porous metal article using a powder metallurgy forming process is provided which eliminates the conventional steps associated with removing residual carbon. The method uses a feedstock that includes a ferrous metal powder and a polycarbonate binder. The polycarbonate binder can be removed by thermal decomposition after the metal article is formed without leaving a carbon residue.
    Type: Grant
    Filed: January 13, 2011
    Date of Patent: May 27, 2014
    Assignee: UT-Battelle, LLC
    Inventor: Curtis Jack Miller
  • Publication number: 20130343946
    Abstract: A method for manufacturing a sintered rare-earth magnet having a magnetic anisotropy, in which a very active powder having a small grain size can be safely used in a low-oxidized state. A fine powder as a material of the sintered rare-earth magnet having a magnetic anisotropy is loaded into a mold until its density reaches a predetermined level. Then, in a magnetic orientation section, the fine powder is oriented by a pulsed magnetic field. Subsequently, the fine powder is not compressed but immediately sintered in a sintering furnace. A multi-cavity mold for manufacturing a sintered rare-earth magnet having an industrially important shape, such as a plate magnet or an arched plate magnet, may be used.
    Type: Application
    Filed: August 26, 2013
    Publication date: December 26, 2013
    Inventors: Masato SAGAWA, Hiroshi NAGATA, Osamu ITATANI
  • Publication number: 20130285778
    Abstract: There are provided a rare-earth permanent magnet and a manufacturing method thereof capable of preventing deterioration of magnet properties. In the method, magnet material is milled into magnet powder. Next, a mixture is prepared by mixing the magnet powder and a binder made of long-chain hydrocarbon and/or of a polymer or a copolymer consisting of monomers having no oxygen atoms. Next, the mixture is formed into a sheet-like shape so as to obtain a green sheet. After that, the green sheet is held for a predetermined length of time at binder decomposition temperature in a non-oxidizing atmosphere so as to remove the binder by causing depolymerization reaction or the like to the binder, which turns into monomer. The green sheet from which the binder has been removed is sintered by raising temperature up to sintering temperature. Thereby a permanent magnet 1 is obtained.
    Type: Application
    Filed: March 15, 2012
    Publication date: October 31, 2013
    Inventors: Keisuke Taihaku, Katsuya Kume, Toshiaki Okuno, Izumi Ozeki, Tomohiro Omure, Takashi Ozaki
  • Patent number: 8551395
    Abstract: A method for preparing a metal-based part, the method comprising applying a slurry to a surface of a temporary substrate to thereby form a slurry-coated temporary substrate, wherein the slurry comprises a Co-, Ni-, or Fe-based metal-based material, a binder, and a solvent; drying the slurry-coated temporary substrate to remove the solvent and to thereby form a coating layer having green strength; heating the coating layer to remove the binder; heating the coating layer to sinter the metal-based material into a continuous metal alloy layer; and separating the substrate from the coating layer. A powder metallurgy preform comprising a powder metallurgy green coating on a preform substrate.
    Type: Grant
    Filed: May 28, 2009
    Date of Patent: October 8, 2013
    Assignee: Kennametal Inc.
    Inventors: Abdelhakim Belhadjhamida, Donald Williams, John Davies
  • Patent number: 8524147
    Abstract: A process for producing powder green compacts includes centrifugally compacting a slip containing a material powder, a binder resin and a dispersion medium in a mold, into a compact containing the material powder and the binder resin. A process for producing sintered compacts includes sintering the green compact. A powder green compact contains a material powder and a binder resin, the binder resin being present between particles of the material powder and binding the material particles. A sintered compact is obtained by sintering the green compact.
    Type: Grant
    Filed: March 27, 2008
    Date of Patent: September 3, 2013
    Assignees: Hiroshima University, Alloy Industries Co., Ltd.
    Inventors: Hiroyuki Suzuki, Yoshinobu Shimoitani